Device and method for manufacturing an article of clothing with a sag-preventive measure and an article of clothing with a sag-preventive member

ABSTRACT

It is an object of this invention to facilitate manufacturing a sag-preventive member. This invention relates to an article of clothing, a method of manufacturing the article of clothing, and the manufacturing device, on which a sag-preventive member is installed so that the layer sheet  1  comprising the adhesive layer  12  having an adhesive strength and flexibility and the film layer  11  is designed to be installed on the article of clothing with the film layer  11  facing the cloth  2  side.

BACKGROUND OF INVENTION

[0001] This invention relates to an article of clothing with a sag-preventive member.

[0002] A typical example of clothing with a sag-preventive member is a stocking. For a stocking, as the traditional sag-preventive member, silicon gum may directly be coated on the inner surface of the stocking in the vicinity of the opening and then the silicon is hardened.

[0003] However, since the traditional sag-preventive member is produced by being coated directly on the inner surface of the finished stocking material, a process for coating requires more time and effort; liquid silicon gum may exude onto the outer surface of the stocking material, which reflects on its appearance; and the thickness of the coated silicon gum is not approximately equal at every portion, which gives an uncomfortable feeling to the user.

[0004] Further, the traditional sag-preventive member on the article of clothing has a traditional sag-resistance; however, it does not have an adhesive strength. Hence, if the traditional sag-preventive member is softly or loosely fit on a surface such as human skin, it does not function sufficiently to prevent sagging.

[0005] In addition, in another traditional process of manufacturing a stocking, a silicon gum is coated on the material to be the sag-preventive portion of the stocking in the vicinity of its opening, and the silicon gum coated material is sewn on the stocking.

[0006] However, since the silicon gum coated material and the stocking itself are different materials, the process is more complex and it becomes a common problem that the color of both materials do not perfectly match.

OBJECT OF THE INVENTION

[0007] This invention is made to resolve the above-mentioned problems, and to that end, an object of the invention is to provide clothing with an effective sag-preventive effect, to facilitate the manufacture a sag-preventive member, and to provide a sag-preventive member with an approximately even surface.

[0008] More specifically, this invention is a method for manufacturing clothing with a sag-preventive member, wherein a layer sheet comprising an adhesive layer which has a degree of tack, an adhesive strength and flexibility and a film layer which has flexibility is installed on the article of clothing with the film layer facing the article of clothing.

[0009] This invention further is a method for manufacturing an article of clothing with a sag-preventive member as above, wherein the layer sheet is sewn on the article of clothing.

[0010] This invention further is a method for manufacturing an article of clothing with a sag-preventive member as above, wherein the film layer is a hot-melt material, and the film layer is welded on the article of clothing.

[0011] This invention further is a method for manufacturing an article of clothing with a sag-preventive member, wherein a layer sheet comprises an adhesive layer which has a degree of tack, an adhesive strength and flexibility and a film layer which has flexibility, the layer sheet covers a peripheral surface of a core member with the film layer facing opposite to the peripheral surface of the core member, the peripheral surface of core member faces an inner surface of the article of clothing, and the article of clothing and the film layer are heated and pressed for said film layer to be welded on the article of clothing.

[0012] This invention further is a method for manufacturing an article of clothing with a sag-preventive member, wherein a core member is covered with the article of clothing with an inner surface of the article of clothing wrapping around a peripheral surface of the core member, a layer sheet comprising an adhesive layer which has a degree of tack, an adhesive strength and flexibility and a film layer which has a flexibility and is hotmeltable, is placed with said film layer facing the article of clothing, and the article of clothing and the film layer are heated and pressed for said film layer to be welded on the article of clothing.

[0013] This invention further is a device for manufacturing an article of clothing with a sag-preventive member, wherein comprises a core member, on which an inner surface of an article of clothing covers, a pressurizing member, which presses a layer sheet, comprising an adhesive layer which has a degree of tack, an adhesive strength and flexibility and a film layer which has flexibility and is hot-meltable, and the article of clothing to be welded together, and a heating means to heat the film layer.

[0014] This invention further is an article of clothing with a sag-preventive member, wherein a layer sheet, comprising an adhesive layer which has a degree of tack, an adhesive strength and flexibility and a film layer which has flexibility, is installed on the article of clothing with the film layer facing the article of clothing.

[0015] This invention further is an article of clothing with a sag-preventive member as above, wherein the layer sheet is sewn on the article of clothing.

[0016] This invention further is an article of clothing with a sag-preventive member as above, wherein the film layer is made of hot-melt materials, and the film layer is welded on the article of clothing.

[0017] This invention still further is an article of clothing with a sag-preventive member as above, wherein the layer sheet has openings.

[0018] This invention yet further is an article of clothing with a sag-preventive member, wherein a layer sheet, comprising an adhesive layer which has a degree of tack, an adhesive strength and flexibility and a film layer which has flexibility and is hot-meltable, is welded on an inner surface of clothing with the film layer facing the article of clothing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The above and other objects and the attendant advantages of the present invention will become readily apparent by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0020]FIG. 1 is an installation view of the layer sheet on the article of clothing by sewing;

[0021]FIG. 2 is an installation view of the layer sheet on the article of clothing by the heatable material;

[0022]FIG. 3 is an installation view of the layer sheet on the article of clothing by the hot air;

[0023]FIG. 4 is an explanation view of the layer sheet covering the core member;

[0024]FIG. 5 is an installation view of the layer sheet on the article of clothing by way of the core member;

[0025]FIG. 6 is an explanation view of the layer sheet covering the core member; and

[0026]FIG. 7 is another installation view of the layer sheet on the article of clothing by way of the core member.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0027] In the following section, an embodiment of this invention is explained with reference to the drawings.

[0028] Examples of an article of clothing with a sag-preventive member may be socks, stockings, brassiere, under short pants, pantyhose, a swimming suit, a sport wear, and what not, if with a sag-preventive member. To take a stocking as an example, a sag-preventive member may be installed on the inner surface of the stocking in the vicinity of the opening, and to take a brassiere as an example, it may be installed on the inner circumferential surface of the brassiere.

[0029] The sag-preventive member comprises an adhesive layer which has a degree of tack, an adhesive strength and flexibility and a film layer which has flexibility. It prevents sagging of the article of clothing by its an adhesive strength and adjusts itself as the article of clothing elongates and shrinks by its flexibility.

[0030] A layer sheet is a sheet made by laminating an adhesive layer and a film layer and is formed in a various shapes such as a constant width tape, circular sheet, and polygonal sheet.

[0031] The adhesive layer has an adhesive strength and flexibility, and it is preferable that it regains its degree of tack, adhesive strength after washing as necessary. It may be made in clear, white, or other colors, and the color should be selected as applicable.

[0032] An adhesive strength is caused as a result of the contact between the adhesive layer and the object such as human skin. It also has a sagging frictional resistance between the adhesive layer and the object as well as an against force which prevents the adhesive layer coming off from the object.

[0033] A peeling adhesive strength is preferably more than approximately 50 gf (according to the explanation of “Adhesive strength of 180 degree peeling against the test plate” in “Testing method of pressure sensitive adhesive tapes and sheets”, JIS-Z-0237 (1991).

[0034] The film layer has flexibility which enables the sag-preventive member to be adjusted as the article of clothing elongates and shrinks and a strength sufficient to maintain itself without cracking or breakage when the article of clothing elongates and shrinks. It may be made in clear, white, or other colors, and the color should be selected as applicable. In addition, if the film layer is designed to be hot-melted, the layer sheet with the film layer may be heated to be welded on the article of clothing.

[0035] For elongation in respect to flexibility of the layer sheet, the strength of the layer sheet is sufficient if the layer sheet on the article of clothing elongates and shrinks without cracking or breakage, and approximately 100% or more is preferable according to the explanation in “Testing method of pressure sensitive adhesive tapes and sheets”, JIS-Z-0237 (1991).

[0036] The layer sheet has vent holes which maintain breathable condition. Vent hole ratio is a ratio of the vent holes relative to the surface area of the layer sheet, which may be determined as applicable and may range from approximately 5 to 85%.

[0037] An adhesive layer is to have an adhesive strength and flexibility, which may be made of polymeric material. For example, a thermosetting or thermoplastic polyurethane, a synthetic rubber, a natural rubber, acrylic, silicon, and what not, may be used. For instance, a polyurethane adhesive layer may be composed of a combination of polyol component and isocyanate component.

[0038] Approximately 200-5,000 molecular weight of, for example, diol, triol, and tetraol may be employed as a polyol component. For a diol component, polytetramethylene etherglycol is a typical component, in which ethylene oxide or propylene oxide is added regarding polyethylene glycol and diethylene glycol as starting materials. For tetraol, a component, in which ethylene oxide or propylene oxide is added regarding glycerol and trimethylolpropane as starting materials, may be employed. For tetraol, a component regarding, for example, pentaerythritol, ethylene diamine, and toluene diamine as starting materials, may be employed. These polyol may be employed as a single component or multi-component or may be combined with approximately 200 molecular weight or less of diol (etherglycol, 1,4-butadiol, 1,6-hexanediol, etc.).

[0039] For isocyanate component, 4,4′-diphenylmethane diisocyanate (MDI), xylilene diisocyanate, isophorone diisocyanate, hexamethylene diisocyanate, hydrogenation MDI, and what not may be employed. In addition, these isocyanate may be denatured by carbodiimide reaction. Further, a portion of these isocyanate may be prepolymer with polyol-reacted isocyanate base at its end.

[0040] General catalyst, which helps urethane-reaction, may be used. Typical catalysts are organic tin catalyst, organic lead catalyst, amine catalyst, carboxylates, and what not. A component other than a catalyst, such as a blowing agent, surfactant, dye, pigment, weathering agent, plasticizer, dehydrating agent, and what not, may be adjoined to such as the above-mentioned polyol component and isocyanate component. For instance, polyol component may be prepared by GL-3000 (polyether polyol-Sanyo Kasei Co.): 73.0 weight ratio, PEG-400 (polyether glycol-Sanyo Kasei Co.): 12.8 weight ratio, DBTDL (dibutyltindilaurate): 0.01 weight ratio. Isocyanate component is MDI (4,4′-diphenylmethane diisocyanate): 14.2 weight ratio. Mixing these polyol component and isocyanate component results in an adhesive layer with an adhesive strength and flexibility.

[0041] A film layer has flexibility and a strength sufficient to maintain itself without being cracked or broken while it is welded on the article of clothing. Polyurethane, polyethylene, polypropylene, and what not, may be employed for the film layer. The thickness may be determined by types of clothing and the applications, and it may be, for example, approximately 30-200 μm.

[0042] If the film layer is designed to be able to hot-melt, it facilitates the installation of the sag-preventive member on the article of clothing. A melting point of the hot-melt depends upon the characteristics and manufacturing process of the article of clothing, and it may be, for example, approximately 100-180 degrees (centigrade).

[0043] For example, MF-150T-AH (Nisshinbo Industries Inc.) may be employed for a polyurethane film layer. Thickness of the layer may be approximately 150 μm, and melting point of the layer may be approximately 130 degrees (centigrade).

[0044] Manufacturing of a Layer Sheet

[0045] A layer sheet is a sheet made by laminating an adhesive layer and a film layer. For the above-described urethane layer, in the method of manufacturing the layer sheet, polyol component is prepared and approximately 142 gram (g) of isocyanate MDI is added to approximately 858.1 g of that polyol component. Then, the mixture of polyol component and isocyanate component is mixed well for approximately 30 seconds.

[0046] Next, the mixture is applied on the film layer. For example, in the method of application, the mixture is applied on the hot-melt polyurethane film layer of approximately 500 millimeters (mm)×4 meters to create the thickness of approximately 0.5 mm. The mixture applied layer is maintained horizontal and is heated at approximately 80 degrees (centigrade) for approximately 5 minutes, so that the applied polyurethane adhesive layer may be cured. Although the thickness of the adhesive layer in this example is 0.5 mm, it may be decided as types and applications of clothing change.

[0047] A mould releasing paper is affixed on adhesive layer of the finished layer sheet, and the layer sheet is cut in approximately 25 mm width to manufacture approximately 4 meter long tape layer sheet.

[0048] A method of installing a sag-preventive member on an article of clothing is explained next.

[0049] Installation by Sewing

[0050] In case of installing a sag-preventive member on an article of clothing, the layer sheet 1 may be sewn with thread 3 on the cloth 2 as shown in FIG. 1. At that time, the layer sheet 1 is designed to be installed so that the film layer 11 of the layer sheet 1 is to face the cloth 2 side and the adhesive layer 12 becomes a surface side.

[0051] Installation by Heating

[0052] In case that the film layer 11 is a hot-melt layer, for example, as shown in FIG. 2, the layer sheet 1 is placed on the base 5 with the film layer 11 facing upward; the cloth 2 of the article of clothing is placed on the layer sheet 1; and the heatable material 4 is placed on and presses the cloth 2 and the film layer 11 for heating the film layer 11 to be melted. However, depending upon types of cloth 2, the cloth 2 may be placed on the base 5; the layer sheet 1 is placed on the cloth 2 with the film layer facing downward; and the heatable material 4 is placed on and presses the cloth 2 and the film layer 11 for heating the film layer 11 to be melted to weld the layer sheet 1 on the cloth 2.

[0053] Yet, as in FIG. 3, the cloth 2 of clothing and further the layer sheet 1 with the film layer 11 facing downward, are placed on the base 5, and the layer sheet 1 is to be pressed by a part of the pushing roll 6. The layer sheet 1 is placed on the cloth 2 with the film layer 11 facing the cloth 2 and is to be pulled downwardly. Hot air from a heating means is blown onto the film layer 11 to melt the film layer 11, and the pushing roll 6 is rotated to quickly press the film layer 11 to be welded on the cloth 2. Here, the hot air is adjusted in accordance with the durability of the article of clothing relative to the cloth temperature, characteristics of the article of clothing, manufacturing speed, and what not, and it may be for example from approximately 150 to 500 degrees (centigrade). For the device, for example, “Hot Air Sealing” QHP-805, manufactured by Queen Light Co. Ltd. may be used.

[0054] Installation with a Core Member

[0055] For example, as shown in FIG. 4, a core member 7 covered by the cloth 2 of the article of clothing is prepared in the predetermined condition, and the hot-melt layer sheet 1 is installed on the core member 7 with the film layer 11 facing the surface side (opposite to the peripheral surface of core member). At the portion on the core member 7 where the layer sheet 1 is installed, the suction holes 71 may be formed, which facilitate the arrangement of the layer sheet I when the layer sheet 1 is held by vacuum from inside of the core member 7.

[0056] For the core member 7, at least a part of the core member 7 is covered by the cloth 2 of the article of clothing; the shape is determined by types of clothing; and materials such as iron, aluminum, and resin, for example, may be employed.

[0057] For an article of clothing with a tubular portion such as a stocking, the core member 7 may be designed to be a tubular member as shown in FIG. 5, and the layer sheet 1 is to be easily installed on the inner surface of the stocking adjacent to the opening 21.

[0058] In that case, the opening 21 of the stocking is to cover the core member 7 from its one end, so that the layer sheet 1 may be located on the particular position of the opening 21 of the stocking. Next, the heatable material 4 is placed on and presses the stocking for melting the film layer 11 to be installed on the inner surface of the stocking. However, depending upon types of clothing, a stocking reversed from inside, the film layer 11 of the layer sheet 1, and the adhesive layer 12 are arranged respectively, and the heatable material 4 is placed on and presses the adhesive layer 12 for the installation.

[0059] Adhesive strength of the adhesive layer 12 to be installed on the stocking is preferably, approximately 50 gram force (gf) or more, more preferably, approximately 100 gf or more, and at most the amount not giving uncomfortable feeling to the user when taking off. Further, the tensile elongation of the adhesive sheet is preferably, approximately 100% or more and more preferably, approximately 200% or more.

[0060] The heatable material 4 has a heat generating function, and many types of materials such as iron, aluminum, and rubber may be employed. For a heat generating method, a sheet heating element alone or a heatable material with a heating element inside may be used as long as it has a heat generating function.

[0061] Further, as shown in FIGS. 6 and 7, the layer sheet 1 may be installed on the article of clothing by placing the core member 7 vertically, setting the layer sheet 1 on the particular portion of the core member 7, covering the cloth on the core member 7 from the above, and heating the film layer 11 by the heatable material 4. Further, depending upon types of cloth, the cloth 2 may be arranged underneath the layer sheet 1.

[0062] This invention has the following advantages:

[0063] A sag-preventive member of this invention has an adhesive strength, and therefore sagging is prevented without tightening the article of clothing on the object.

[0064] An adhesive layer may be preset on the film layer. Hence, the thickness of the adhesive layer is uniform.

[0065] If a film layer is made of a hot-melt layer, it facilitates the installation of the adhesive layer on the article of clothing.

[0066] If a film layer is a hot-melt layer, it avoids liquid silicon gum from being exuded onto the outer surface of the cloth, thereby maintaining its appearance.

[0067] If a film layer is prepared in a tape, installing the layer by sewing maintains its appearance.

[0068] Since a layer sheet may be installed on the finished clothing, the manufacturing process is simplified and the color may be matched.

[0069] It is readily apparent that the above-described has the advantage of wide commercial unity. It may be understood that the specific form of the invention hereinabove described is intended to be representative only, as certain modifications within the scope of these teachings will be apparent to those skilled in the art.

[0070] Accordingly, reference should be made to the following claims in determining the full scope of the invention. 

1. An article of clothing with a sag-preventive member, including a layer sheet, comprising a means for preventing sag having an adhesive strength and flexibility and a film layer having flexibility, said layer sheet being fixedly installed on said article of clothing with said film layer facing said article of clothing, and said means for preventing sag facing a body of a wearer and being removably adherent thereto.
 2. The article of clothing with a sag-preventive member, according to claim 1, wherein said means for preventing sag is a polyurethane layer, a synthetic rubber layer, a natural rubber layer or an acrylic layer.
 3. The article of clothing with a sag-preventive member according to claim 1 wherein said layer sheet is sewn onto said article of clothing.
 4. The article of clothing with a sag-preventive member according to claim 1 wherein said layer sheet has openings.
 5. An article of clothing with a sag-preventive member, including a layer sheet, comprising a means for preventing sag having an adhesive strength and flexibility and a film layer having flexibility and being hot-meltable welded on an inner surface of clothing with said film layer facing said article of clothing, and said means for preventing sag facing a body of a wearer and being removably adherent thereto.
 6. The article of clothing with a sag-preventive member, according to claim 5 wherein said means for preventing sag is a polyurethane layer, a synthetic rubber layer, a natural rubber layer or an acrylic layer.
 7. The article of clothing with a sag-preventive member according to claim 5 wherein said film layer is made of hot-melt material, and said film layer is welded on said article of clothing.
 8. The article of clothing with a sag-preventive member according to claim 5 wherein said layer sheet has openings. 